Operating Instructions Stud Welder BMS-8N

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Operating InstructionsStud WelderBMS-8NR

ROperating InstructionsStud WelderBMS-8NSerial number*Stud Welder BMS-8N* Please enter the serial number, so that this data is immediately available if youneed service support.Heinz Soyer Bolzenschweißtechnik GmbHEtterschlagInninger Straße 1482237 WörthseePhone08153 - 885 - 0Fax 08153 - 8030Telex 5270 295 heso d

RSOYER is a registered trade mark of Heinz Soyer BolzenschweißtechnikGmbH.It is prohibited to transmit or reprint this document, as well as to utilize or disclose its contents, unless this hasbeen expressly granted.Non-compliance with this regulation is liable to compensation. All rights reserved, particularly in the case of apatent grant or GM registration.We have certified that the contents of this pamphlet correspond to the hard- and software described. Deviations,however, cannot be excluded, so that we cannot warrant for absolute compliance. The data in this documentation, however, have been verified regularly and necessary corrections will be incorporated in future impressions.We appreciate any suggestions for improvement.Date of issue revision 1:Aug. 1, 2000 Heinz Soyer Bolzenschweißtechnik GmbH 1995 · All rights reservedSubject to technical alterationsPrinted in the Federal Republic of Germany

REC Conformity Declarationin compliance with EC Directive on Machinery 89/392/EEC, annex IIAProducer:Heinz Soyer Bolzenschweißtechnik GmbHEtterschlagInninger Straße 14D-82237 WörthseeDeclaration:We herewith declare that the machine described in the following and theversion available on the market correspond in design and construction to thefundamental safety and health requirements stipulated by the EC Directive onMachinery. Any modification of this machine without confirmation shallautomatically annul this declaration.Designation of machine:Stud welder with tip ignitionMachine type:BMS-8NMachine no.:Applicable EC directives:EC Directive on Machinery (89/392/EEC) in the version 91/368/EECEC Directive on Low Voltage (73/23/EEC)EC Directive on Electromagnetic Compatibility (89/336/EEC) in the version93/31 EECApplied harmonisedstandards,in particular:EN 292-1 and EN 292-2, EN 60 204-1EN 60 974-1Applied national standardsand technical specifications,in particular:VBG 1, VBG 5,Date:December 1, 1997VDE 0544Producer's signature:Signer's function:Technical Management

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6G e n e r a l 1-1The following should be principally observed . 1-1Application 1-2Information on the product 1-2Type plate 1-2Information on the documentation 1-3Chapters of operating instructions 1-3Information on operating instructions 1-4Conduct in the case of malfunctions 1-4Contacts and service address 1-422.12.22.32.42.5Description of stud welder2-5Tip ignition technology 2-5Stud welder set-up 2-5Dimensions 2-6Technical data 2-7Block diagram 4Safety instructions3-9Description of reference signs in the operating instructions 3-9Staff qualification and training 3-10Dangers in the case of non-compliance with safety instructions 3-10Safety-conscious working 3-10Safety instructions for the operator/user 3-11The following should be observed before starting the system . 3-11Before starting welding . 3-12Safety precautions at installation site 3-12Working with the stud welder 3-13Safety instructions for maintenance, inspection and assembly works 3-13Unauthorized retrofit and spare parts production 3-13Inadmissible operating methods 3-14Stopping the stud welder 3-14The "S" symbol 3-144Installation of stud .25.2.35.35.4Initiation5-16Total view 5-16Operating elements 5-17Display elements 5-17Connecting elements 5-17Symbols 5-18Fuse elements 5-18Preparation for initiation 5-19Earth connection 5-19Connection of stud welding pistol 5-19Mains supply 5-19Operation 5-20Welding parameters 5-20Revision 1i

6.5.4Quality control6-21General 6-21Demands on the company 6-21Proof of qualification 6-21Type and scope of test 6-21Standard work test 6-22Simplified work test 6-22Test execution 6-22Production of samples 6-22Visual inspection 6-22Tensile test 6-23Bend test 6-2377.17.27.3Maintenance7-24Stud welder 7-24Replacement of components 7-24Fuses 7-2588.18.28.38.48.58.6Spare parts 8-26Spare parts list for stud welder BMS-8N - Overview 8-26Exploded view of stud welder BMS-8N - Overview 8-27Spare parts list for stud welder BMS-8N - View A 8-28Exploded view of stud welder BMS-8N - View A 8-29Spare parts list for stud welder BMS-8N - View B, C and D 8-30Exploded view of stud welder BMS-8N - View B, C and D 8-3199.19.2Malfunctions9-32Error codes 9-33Troubleshooting 9-3410Transport and storage10-3611List of standards and guidelines11-3712Terms of warranty12-38Appendix A/PS-1 and PS-1K - Tip ignition11.11.21.31.4Adjustment of stud welding pistolA-1Adjustment of stud holder A-1Installation of stud holder into stud welding pistols PS-1 and PS-3K A-2Installation of stud holder into stud welding pistols PS-1K and PS-0K A-3Adjustment of spring pressure A-422.12.22.3InitiationA-5Total view A-5Connecting stud welding pistols to stud welder A-6Operation A-633.13.2Spare parts A-7Spare parts list for stud welding pistol PS-1K A-8Exploded view of stud welding pistol PS-1K A-9Revision 1ii

RGeneral1General1.1 The following should be principally observed .With this stud welder you have purchased a product which is state-of-the art technology fully complies with the current safety requirements and enables successful working.Before putting the stud welder into operation, always observe the following : Store the operating instructions in a place accessible to every operator Ensure that the respective operator has read and understood the operatinginstructions prior to installation. Each operator should confirm this by signature Prevent the stud welder being operated by unauthorized persons Only trained personnel may operate the stud welderᏘMORTAL DANGERPersons with pacemakers must not operate the stud welder and must notstay in the vicinity of the stud welder while it is running.Ensure that the stud welder is not operated near electronically sensitive lifesupporting equipment, such as in intensive care units in hospitals.WARNINGKeep sufficient distance from electronic devices. When stud welding, highlyintensive electromagnetic fields are created which may permanently damagethese devices (e.g. television sets). Moreover, observe the safety instructions in chapter 3. Call a doctor in case of an accident.ᏘMORTAL DANGERThe "S" symbol is the symbol for welding current sources permitted foroperation with increased electric danger. The "S" symbol on our studwelders refers exclusively to the welding current circuit and not to thecomplete stud welder.Revision 11-1

RGeneral1.2 ApplicationThe SOYER stud welder BMS-8N with tip ignition allows you to weld pins andthreaded studs of M3 - M8 or Ø 3 - 7.1 mm as well as numerous variousfastening elements made of steel and stainless steel (see chapter 2.4, Technical Data). It is also possible to weld fastening elements made of aluminium andbrass depending on the respective requirements.The visible side of the workpiece is spared to a large extent from pressuremarks or deformations, so that even thin sheet metals under 1 mm sheetthickness retain their decorative appearance.If you need consultation or assistance in solving problems, please contacteither our parent company or our field engineers.1.3 Information on the productManufacturerHeinz Soyer Bolzenschweißtechnik GmbHEtterschlagInninger Straße 14D-82237 //www.soyer.de (national)http://www.soyer.com (international)Product designationStud welder BMS-8NCountry of originGermany1.4 Type plateThe type plate is located on the rear side of the stud welder. It contains thefollowing information: 1-2Manufacturer's nameManufacturer's addressCountry of originProduct designationMethod of weldingDate of constructionProduction numberPerformance dataMains connection valuesRevision 1

RGeneral1.5 Information on the documentationThe following operating instructions are supplied with the BMS-8N stud welder: Operating instructions for stud welder BMS-8NOrder no.: P00298For repeat-orders please contact:Heinz Soyer Bolzenschweißtechnik GmbHEtterschlagInninger Straße 14D-82237 5 heso dE-mailexport@soyer.deverkauf@soyer.de1.5.1 Chapters of the operating instructionsThe operating instructions describe the initiation and operation of the studwelding system under normal conditions and comprise the following chaptersin detail: Chapter 1 "General"Information on application and product, as well as supplementary information Chapter 2 “Description of stud welder"Description of tip ignition technology and of the stud welder Chapter 3" Safety instructions"All safety regulations which are relevant with regard to initiation and operation of the stud welding system Chapter 4 "Installation of stud welder" Chapter 5 "Initiation" Chapter 6 "Quality control" Chapter 7 "Maintenance"Maintenance measures Chapter 8 "Spare parts" Chapter 9 "Troubleshooting"Errors, possible causes and remedies Chapter 10 "Transport and storage" Chapter 11 "List of standards and guidelines" Chapter 12 "Terms of warranty"Revision 11-3

RGeneral1.5.2 Information on operating instructionsLegal relationshipWe draw your attention to the fact that the contents of these operating instructions are neither part of any former or existing arrangement, pledge or legalrelationship nor are designed for modifying the latter. All obligations of HeinzSoyer Bolzenschweißtechnik GmbH result from the respective contract ofpurchase which also comprises the complete and generally valid warranties.These contractual warranty terms are neither extended nor restricted by theimplementation of these operating instructions.WARNINGDo not carry out any activities on the stud welding system without specifically knowing the operating instructions or the respective part. Ensure thatonly qualified personnel familiar with the operating instructions and thenecessary technical activities (training!) operate the system.1.5.3 Conduct in the case of malfunctionsIf malfunctions occur, first try to detect and eliminate the causes according tothe list in chapter 9 "Troubleshooting". In all other cases, contact our servicedepartment.Important informationif service is requiredIf you require our service, please make sure that you supply the followinginformation: Customer numberProduct designationSerial numberYear of constructionOptionsMaterial of stud and workpieceStud dimensionsThis information will help us both to save time and unnecessary costs, e.g.caused by delivering the wrong spare parts.1.6 Contacts and service addressIf you have any questions regarding the operation of the stud welding system,retrofits or if you require service, please contact your responsible service officeor the following address:Heinz Soyer Bolzenschweißtechnik GmbHEtterschlagInninger Straße 14D-82237 5 heso dE-Mailexport@soyer. deverkauf@soyer. de1-4Revision 1

RDescription of stud welding system2Description of stud welder2.1 Tip ignition technologyThe SOYER stud welding systems with tip ignition run according to theprinciple of capacitor discharge as defined in DVS Leaflet 0903 (GermanWelding Society).This system uses the abrupt discharge of a capacitor battery to generateelectric arc energy.Stud tip touches workpiece. Electric arc isinitiated.Ignited arc generates athin fusion zone on studand workpiece.Stud immerses in weldingpool. Material solidifiesand stud is welded.SZ.0078.EThe electric arc is initiated via the calibrated and close-fit ignition tip on thewelding studs and welding elements. The stud weld base and the oppositesurface of the workpiece are melted on. The stud is then automatically dippedin the thin fusion zone or liquid weld pool. After the immediate solidification ofthe material, an homogenous high-strength joint is produced in an extremelyshort welding time of only 1 - 3 milliseconds (0.001 - 0.003 sec.).2.2 Stud welder set-upThe standard pistol to be connected to the stud welder BMS-8N is the studwelding pistol PS-1K with control cable.Optionally it is possible to connect the stud welding pistols PS-0K, PS-1 andPS-3K. These operating instructions exclusively describe the stud welder BMS8N.For information regarding the stud welding pistols required and their setting,please refer to the respective operating instructions of the stud welding pistols.Revision 12-5

RDescription of stud welding system2.3 DimensionsThe stud welder BMS-8N has a handy and compact design.It has a carrying handle and can be optionally equipped with a shoulder strap.300000120000RØ3Ø4Ø5Ø6Ø7Ø8 70 100 115 140 175 190BMS-8NTÜV RheinlandgeprüfteSicherheitSHeinz Soyer Bolzenschweißtechnik GmbH · Etterschlag · Inninger Str. 14 · 82237 Wörthsee · Tel.: 0 81 53/885-0Depth 320 mmSZ.0124.E2-6Revision 1

RDescription of stud welding system2.4 Technical dataDescriptionBMS-8NWelding rangeM3 - M8 or Ø 3 - 7.1 mmMaterialSteel, stainless steel. Aluminium and brass conditionally,depending on the respective requirementsWelding methodTip ignition according to DVS Leaflet 0903Standard pistolStud welding pistol PS-1KCurrent sourceCapacitor batteryCharging capacity 66,000 µFCharging voltage50 - 200 V infinitely variable up/downWelding time0.001 - 0.003 sec.Welding sequence up to 20 studs/min., depending on stud diameterMains supply115/230 V AC, 50/60 Hz, 10/16 AT shock-proof socket(automatic voltage selection 115/230 V AC)Fuse elementG - fuse link 5 x 20 mm, 2 x 10 A slow, 250 V.The fuse links are integrated in the unit mountingplugs at the rear side of the stud welders.Welding cable3 m highly flexibleEarth cable2 x 3 highly flexibleWeight10 kgColourRAL 5009 azureSubject to technical changesSZ.0125.ERevision 12-7

RDescription of stud welding systemKL19KL181000µF26VDCKL16KL15KL14VentilatorF3 250mAKL13KL125VDCMeasuringpoints KL17F2 1AControlKL11KL10 KL9KL8blueredblueredblueKL202200µF10ATblue130 Cblue20VblueToroidalmains transformerBV 973 701.3green115VyellowwhiteMKL21whiteF1 6.3ATChargeS0115 revision 2Machine kswKL5brownredKL6Ventilator24VDCRelaySP2 5VDCyellow/green KL7Core 254 turnsI/0Core 205 turns10ATNL1Mains supply115/230VAC50/60HzPE2.5 Block diagram of wnbrowngreen100W22RDischargingresistor RrtSKR 130/16 Flat cable26-pin22mF 22mFCore 205 turnsS30E4A22mFGateEarthPistol100W3R9Safety resistorEarth1TriggerPistolCathode915-pole socketPSO105 revision 1Front panel SZ.0178.E2-8Revision 1

RSafety instructions3Safety instructionsThese operating instructions contain basic instructions which have to becomplied with during installation and/or operation. It is therefore absolutelynecessary that these operating instructions are read by the operator andresponsible specialist staff prior to assembly and initiation. They must alwaysbe available at the installation site.Not only the general "safety instructions" listed under this main item, but alsothe special safety instructions e.g. for high temperatures, voltages, etc. listedunder the other main items have to be complied with.3.1 Description of reference signs in the operating instructionsThe non-observance of safety instructions can cause damage to persons.The safety instructions of this manual are marked with the general symbol fordanger safety symbol in compliance with DIN 4844 - W9Warning of electric voltage is specially marked with theᏘsafety symbol in compliance with DIN 4844 - W8In addition to these symbols, the words "DANGER TO HEALTH" or "MORTALDANGER" refer to the degree of a possible danger.Revision 13-9

RSafety instructionsSafety instructions the non-observance of which may endanger the machineand its functions are marked with the terms"CAUTION" or "WARNING".General instructions are marked with the hand symbol. 3.2 Staff qualification and trainingThe staff responsible for operation, maintenance, inspection and assemblymust have the respective qualification for carrying out these works. Field ofresponsibility, competence and the supervision of staff has to be exactlyregulated by the user. If your personnel do not have the necessary knowledge,they have to be trained and instructed. If necessary, this can be done by themanufacturer/supplier on behalf of the welding equipment user. Furthermore,the user must ensure that the contents of the operating instructions are fullyunderstood by the staff.The training and testing institute of welding in Munich (SLV: SchweißtechnischeLehr- und Versuchsanstalt) offers the appropriate training courses for yourpersonnel.3.3 Dangers in the case of non-compliance with safety instructionsThe non-compliance with safety instructions may not only endanger persons,but also the welding system and its environment. Any non-compliance withsafety instructions may result in a complete loss of damage claims.Non-compliance with safety instructions may have the following consequences: Failure of important system functions Failure of prescribed methods for maintenance Danger to persons through electric, mechanic, thermal and acousticinfluences3.4 Safety-conscious workingThe safety instructions listed in this manual, existing national accident prevention regulations and possible international working, operating and safetyregulations of the user must be complied with.3-10Revision 1

RSafety instructions3.5 Safety instructions for the operator/userWhen stud welding, danger may result from electric currentoptical radiationharmful substances (smoke)acoustic shockspraying sparksYou are therefore obliged to restrict the dangers to an inevitable degree and topoint these dangers out to the operator and other persons involved. MORTAL DANGERPersons with pacemakers must neither operate the stud welder nor staynear it.3.6 The following should be observed before starting the system.Before starting the system, pay attention to the following information: Juveniles under the age of 16 years must not operate the stud weldingsystem. Read all of the operating instructions before starting the system. Only qualified personnel are allowed to operate the system. Prevent unauthorized use of the system by children or unqualified personnel. Wear non-combustible, closed working clothes. Wear a leather apron to protect your clothes from welding spatters that aregenerated during the welding process. Wear a head protection when carrying out welding works above your head. MORTAL DANGERWhen welding, do not wear clothes soiled with easily combustiblesubstances such as oil, grease and paraffin oil, etc.Revision 13-11

RSafety instructions Wear gauntlet gloves made of leather. Wear neither rings, watches nor electrically conductive jewellery. Wear protective goggles to protect your eyes from welding spatters andflashes of light that are generated during the process. Wear ear protection. Capacitor discharge generates a loud bang.3.7 Before starting welding . Check the state of all cables before starting to weld. Immediately replace defective cables and cable connections. Ensure that the air apertures of the housing are not covered. Heat accumulation may damage the stud welder.3.8 Safety precautions at installation site When placing the stud welder on tables or similar workshop furniture,ensure that the stud welding system stands firmly and that the table canbear its weight. Make sure mains socket and stud welder are properly earthed. Comply with fire prevention regulations and do not weld in hazardouslocations. Make sure room is well ventilated or extract welding fumes, if necessary. DANGER TO HEALTHWhen welding, fumes and suspended matters may be generated . Bewareof fumes detrimental to health, particularly when using surface-treatedmaterials. If possible, only weld in rooms which are higher than 3 m. As perVBG 15, special regulations are applicable for narrow rooms.3-12Revision 1

RSafety instructions3.9 Working with the stud welder Comply with all accident prevention regulations which apply to the operationof your stud welder One of the accident prevention regulations applicable for studwelders is VBG15 "Welding , cutting and similar workingmethods". For more information, contact the Employer's LiabilityInsurance Association.MORTAL DANGERWhen welding, do not wear clothes soiled with easily combustiblesubstances such as oil, grease and paraffin oil, etc.If an accident happens, switch off the stud welder and disconnect it from the mains supply call a doctor.3.10Safety instructions for maintenance, inspection and assemblyworksOnly carry out maintenanceworks when stud welder hasbeen switched offThe user must ensure that all maintenance, inspection and assemblyworks are only carried out by authorized and qualified technical personnel.Generally, only work at the system when it has been switched off and afterhaving disconnected it from the mains supply. It is indispensable to complywith the procedure for stopping the stud welding system described in theoperating instructions (chapter 3.13).Immediately after having completed your work, re-install and activate all safetyand protective devices.3.11Unauthorized retrofit and spare parts productionThe system may only be retrofitted and modified after consultation with themanufacturer. Original spare parts and accessories authorized by the manufacturer guarantee safety. The use of other parts may result in the cancellation ofwarranty for any consequences thus caused.Revision 13-13

RSafety instructions3.12Inadmissible operating methodsLimit valuesWorking safety of the stud welding system supplied can only be guaranteedwhen the stud welder is used in accordance with its purpose. The limit valuesindicated in the chapter "Technical data" must never be exceeded.3.13Stopping the stud welder Switch off the mains switch (chapter 5.1, item 9) located at the studwelder's rear side. Disconnect the mains plug from the socket. Disconnect- the earth cables (chapter 5.1, item 5)- the control cable (chapter 5.1, item 7)- the welding cable (chapter 5.1, item 6)from the stud welder. Roll up the cables without buckling them. Our tool and gear wagon GW-1 is the optimum solution forinstalling SOYER stud welders and for properly storing weldingpistols, cables, studs, retrofit kits etc. Make sure stud welder cannot be used by unauthorized persons. Check the welding cable and connections of the stud welder for damagesuch as burn-off, mechanical wear etc. and have damaged parts replacedby SOYER customer service.3.14The "S" symbolᏘMORTAL DANGERThe "S" symbol is the symbol for welding current sources permitted foroperation with increased electric danger. The "S" symbol on our studwelders refers exclusively to the welding current circuit and not to thecomplete stud welder.3-14Revision 1

RInstallation of stud welder4Installation of stud welder Only install the stud welder on an even surface. The four anti-vibration padslocated on the bottom of the stud welder guarantee its anti-skid positionand serve as vibration dampers. Although the stud welder is resistant to environmental influences, it shouldbe protected against dampness and dust. Please pay particular attention to the bearing strength of the workshopfurniture and ensure a safe and stable position. Make sure there is sufficient free space around the air apertures. Install the stud welder close to the welding location. Ensure correct connected loads with mains operation. The electrical connecting cable used for mains operation is of adequatelength. Additional extension cables cause a voltage drop, possibly leading tounit disturbances. Ensure sufficient ventilation of the working room when operating the system. Revision 1The housing of stud welder BMS-8N corresponds to safetyclass IP 21. Please observe e.g. that this system of protection isnot suitable for being operated or transported in the rain.4-15

RInitiation5Initiation5.1 Total viewFront view1234000000RØ3Ø4Ø5Ø6Ø7Ø8 70 100 115 140 175 190BMS-8NTÜV RheinlandgeprüfteSicherheitSHeinz Soyer Bolzenschweißtechnik GmbH · Etterschlag · Inninger Str. 14 · 82237 Wörthsee · Tel.: 0 81 53/885-08Rear view9107651112SZ.0126.X1 Function key "Arrow up"Increase of charging voltage2 Charging voltage display3 Function key "Arrow down"Decrease of charging voltage4 LED displays5 Earth cable connectors5-166789101112Welding cable socketControl cable connectionCarrying handleMains switchFusesType plateMains connectorRevision 1

RInitiation5.1.1 Operating elements Mains switch (item 9, chapter 5.1)The mains switch located at the rear side of the stud welder serves to switchthe stud welder on and off. Function key "Arrow up" (item 1, chapter 5.1)The function key "Arrow up" (1) enables continuous increase of the chargingvoltage for larger stud diameters (for setting values, refer to the table). Function key "Arrow down" (item 3, chapter 5.1)The function key "Arrow down" (3) enables continuous decrease of thecharging voltage for smaller stud diameters (for setting values, refer to thetable).5.1.2 Display elements Charging voltage display (item 2, chapter 5.1)The digital display shows the adjusted energy value.(c

Aug 01, 2000 · General 1-2 R Revision 1 1.2 Application The SOYER stud welder BMS-8N with tip ignition allows you to weld pins and threaded studs of M3 - M8 or Ø 3 - 7.1 mm as well as numerous various fastening elements ma

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